CLOSED CIRCUIT COOLING THERMAL STORAGE EVAPORATIVE CONDENSERS COOLING TOWERS SERIES 3000 COOLING TOWERS 1 7
Series 3000 Cooling Towers PROVEN TOTAL PERFORMANCE Series 3000 Cooling Towers meet the demands of today s industrial cooling, air conditioning, and refrigeration systems. Constructed with energy efficient components, these cooling towers deliver independently verified, fully rated thermal performance over a wide range of flow and temperature requirements. Years of operating experience and extensive research and development have resulted in standard design features that satisfy today s environmental concerns, minimize installation costs, maximize year-round operating reliability, and simplify maintenance requirements. Innovative performance-enhancing options and alternate corrosionresistant materials of construction allow each unit to be customized to meet specific project requirements. SERIES 3000 COOLING TOWERS Proven total performance Low energy consumption Long service life Low installed cost Reliable year-round operation Easy maintenance Three-year wrranty on mechanical equipment 2
JE PREMIER SERIES CONSTRUCTION Where the ultimate in corrosion protection and long life is desire, Series 3000 Cooling Towers, provided with JE PREMIER SERIES Construction, have all the benefits of the standard Series 3000, plus: Stainless steel components provide the ultimate in corrosion protection: structural frame welded cold water basin mechanical equipment support fan deck and cylinder hot water basin and distribution covers louver supports Three-year warranty on the entire unit 3
Proven Advantages Low energy consumption With increased environmental concerns and utility deregulation, low energy consumption is an important social issue as well as a signi ficant economic consideration. Series 3000 Cooling Towers feature energy-e fficient components that minimize pow er requirements. High efficiency c Wet Deck Surface with integral eliminators provides maximum air/w ater contact time and low air pressure drop. Additionally, axial flow fans allowthe fan horsepowertobeapproximatel y half that required by comparably sized centrifugal fan units. In addition, alternative low-horsepower models can be selected to further reduce fan power consumption. The Power Train fan drive system, featured as standard on most Series 3000 Cooling Towers, allows fan energy consumption to be further reduced with The exclusive ENERGY -MISER fan System option.the ENERGY-MISER Fan System employs two Independent motors sized to provide energy savings superior to conventional two-speed motors and af ford stand-by protection in the event of a motor failure (see page 9 for details). Long Service Life Frame construction enables standard casing panels and air inlet louvers, w hich are critical links for long se rvice life, to be constructed of corrosion-resistant, fiberglass reinforced polyester (FRP). For applications where abnrmally corrosive conditions exist, or e xtended equipment life is desire Series 3000 Cooling Towers are available in a wide range of constuction alternatives. Galvanized, BAL L TIBOND corrosion Protection System, or Type 304 Stainless Steel are available to meet the corrosion resistance, unit operating life, and budgetar y requirements of any r project (see page 8 for construction alternatives). Low Installed Cost All models mount directly to two parallel I-beams and ship complete with motors and drives factory-installed and aligned. Models 3728A through 31056A and 31132A through 31301A ship in two sections to minimize rigging requirements. The modular concept of the Series 3000 Cooling Tower enable unit to be easily multiplexed for larger installations, to provide a cost-e ffective alternative to field-erected products by eliminating the time and expense associated with site erection. The optional EASY CONNECT Piping Arrangement with BALANCE CLEAN Chamber further reduces field maintenance and installation costs by eliminating overhead piping and piping support requirements. 4
COMPONENTS DESCRIPTION Reliable Year-Round Operation Series 3000 Cooling Towers provide reliable, trouble-free operation in all climates. The exclusive Beltdrive Power Train fan dr ive system is the result of many years experience with cooling tower drive systems. Backed by a three-year fan drive and motor warranty, the Beltdrive Power Train utilizes special corrosion resistant materials of construction and state-of-the-art technology to ensure ease of maintenance and reliable year -round perfo rmance. towers provide a spacious plenum with easy access for visual inspections and maintenance. Oversized access doors in both end walls provide easy access to the unit interior to adjust the make-up float valve, clean the cold water basin and strainer, and service the fan drive system. The wet deck surface is elevated above a sloped cold water basin to facilitate flushing of dirt and debris from this critical area. The water distribution system consists of gravity distribution basins with large orifice nozzles, which greatly reduce clogging and assure constant performance between maintenance intervals. When nozzle cleaning is required, each nozzle can be cleaned in place, or easily removed. Steel distribution system covers are supplied as standard on all Series 3000 Cooling Towers. This feature eliminates exposure of the water to airborne debris which reduces dirt accumulation in the distribution basins. The distribution basin covers are designed for a maximum concentrated live load of 200 pounds. Separate air inlet louvers, a standard feature on all Series 3000 Cooling Towers, provide a critical function for reliable year -round cooling tower operation. In addition to ensuring uniform air distribution throughwet Deck Surface, separate air inlet louvers reduce the potential for excessive scale build-up and damaging ice formations at the air/water interface. Easy Maintenance To obtain optimum performance and maximum service life, it is important that cooling towers be designed to simplify routine cleaning and maintenance requirements. Crossflow cooling This innovative option allows all routine maintenance of the water distribution system to be performed from the unit interior eliminating the need to use the cooling tower fan deck as a working surface to perform routine maintenance. If access to the top of the unit is desired, the purchaser/end-user is cautioned to use appropriate means, complying with applicable safety standards of governmental authorities. 5
Construction Details Heavy Duty Construction Heavy gauge steel frame Alternate materials of construction available Water Distribution System Sturdy steel covers in easy to remove sections Low pump head gravity distribution basins Large orifice, non-clog nozzles Low HP Axial Flow Fans Quiet operation Corrosion resistant aluminum Optional low sound fans available FRP Casing Panels Corrosion resistant Maintenance free UV resistant finish Wet Deck Surface with Integral Drift Eliminators Polyvinyl chloride (PVC) Impervious to rot, decay or biological attack Elevated above the cold water basin for easy maintenance Oversized Access Door Inward swinging doors on each end wall with easy latch handles 6
Beltdrive Power Train Premium quality, solid backe d, multi-groove belt Corrosion resistant cast aluminum she aves Heavy duty bearings (280,000 hour Three -year motor and drive warranty Principle of Operation Water from the system heat source enters the Series 3000 Cooling Tower through two inlet connections located on the top of the unit. The water circulates through the hot water basins, where non-clog diffuser nozzles distribute the water uniformly over the wet deck surface. Simultaneously, air is drawn through air inlet louvers and across the wet deck surface, causing a small portion of the water to evaporate. Evaporation removes the heat from the remaining water. The cooled water then flows into the cold water basin and returns to the heat source. FRP Air Inlet Louvers Corrosion resistant UV resistant finish Prevent water splash-out Maintenance free Minimize scaling potential on face of wet deck Cold Water Basin Sloped cold water basin below wet deck sections for easy cleaning Suction strainer with anti-vortex hood Adjustable water make-up assembly Lifting ears for easy installation 7
Construction Alternatives Standard Corrosion Resistant Constrruction All steel panels and structural elements of the Series 3000 Cooling Tower are constructed of hea vy gauge hot-dip galvanized steel. A zinc-rich primer is applied to the cut edges of all hot-dip galvanized components prior to assembly. Casing panels and air inlet louvers, which are critical links in the life expectancy of a cooling tower, are constructed of UV-resistant, fiberglass reinforced polyester (FRP). This standard construction will provide reliable cor rosion protection and long life for most industrial cooling, air conditioning, and refrigeration applications. Optional Corrosion Protection System The Corrosion Protection System is an advancement in materials engineering developed by OMRAN specificall y for increased protection from adverse operating conditions.the manu facturing process fuse bonds a special hybrid pol ymer to all hot-dipped galvanized steel components of the cooling towe r, extending the life of the base material. Optional Stainless Steel Cold Water Basin A welded, Type 304 stainless steel basin is available to increase leak protection and corrosion protection of this critical component. All seams between panels inside the cold water basin are welded. The basin is leak tested at the factory and is provided with a three-year leakproof guarantee. The steel panels and structural members above the cold water basin can be constructed of the standard hot-dipped galvanized steel or the optional Corrosion Protection System. Optional JE PREMIER SERIES Construction Series 3000 Cooling Towers provided with JE PREMIER SERIES Construction are designed for applications exposed to extremely corrosive conditions or where the ultimate in corrosion protection and long life are desired. All steel panels and structural elements, including the structural frames, louver supports, cold water basin, hot water basins and covers, fan deck,fan cylinde r, and mechanical equipment supports are constructed of Type 304 Stainless Steel. All seams bet ween panels inside the cold water basin are welded.the basin is leak tested at the factory and is provided with a three-year leakproof guarantee. Casing panels and air inlet louvers are constructed of corrosion and UV resistant fiberglass reinforced polyester (FRP). 8
Custom Features and Options Low Sound Operation As society becomes increasingly concerned over the quality of its environment, sound is an important consideration in the selection and location of sound generating equipment. The mechanical equipment on Series 3000 Cooling Towers is carefully selected to produce optimum cooling tower thermal performance with minimal sound levels. The low sound levels generated by Series 3000 Cooling Towers make them suitable for installation in most environments. For very sound sensitive installations, Series 3000 Cooling Towers are available with a low-sound fan option which significantly reduces the sound levels generated from the tower with minimal impact on the r mal performance. ENERGY - MISER Fan System Reduced operating costs can be achieved during off-peak operation by taking advantage of ENERGY-MISER F an System option. ENERGY-MISER F an System is an energysaving, capacity control alternative to two-speed motors. It consists of two standard, single-speed fan motors and drive assemblies. One drive assembly is sized for full speed and load, and the other is sized approximately 2/3 speed and consumes only 1/3 the design horsepower. This configuration allows the system to be operated like a two-speed motor, but with the reserve capacity of a standby motor in the event of a failure. Controls and wiring are the same as those required for a two-speed, two-winding motor. Significant energy savings are achieved when operating at low speed during periods of reduced load and/or low wet bulb temperatures. For extremel y sound sensitive installations, factory designed, tested and rated sound attenuation is available for both the air inlet and discharge of Series 3000 Cooling Towers. Consult your local OMRAN Sales Representative for selection and application information on this unique optional feature. ENERGY-MISER Fan System Series 3000 Cooling Towers with discharge sound attenuation. 9
Basinless Unit Construction The basinless unit construction option enables Series 3000 Cooling Towers to be directly applied to projects utilizing new or existing concrete cold water basins. This custom feature, available exclusive ly on OMRAN Series 3000 CoolingTowers, reduces maintenance costs by eliminating the redundant integral basin from traditional units. It simplifies piping and pumping requirements of multi-cell installations, enhances stringent equipment wind and seismic requirements and provides a cost-effective solution for many fielderected cooling tower replacement projects. Basinless Series 3000 Cooling Tower on a concrete basin. EASY CONNECT Piping Arrangement with BALANCE CLEAN Chamber This exclusive OMRAN option simpli fies water inlet piping and reduces routine maintenance on Series 3000 Cooling Towers. A single water inlet connection, located on the side or bottom of each unit, eliminates the need for overhead piping and piping supports. The BALANCE CLEAN Chamber features an integral strainer which pre vents large debris from being ca rried to the hot water distribution basins. The BALANCE CLEAN Chamber automatically balances flow within each cell, eliminating the need for flow balancing valves. The unique design of the water distribution system enables all routine maintenance to be performed from the unit interior thereby eliminating the need to use the cooling tower fan deck as a working surface to perform routine maintenance of the water distribution system. Velocity Recovery Stacks Velocity recovery stacks, previously used primarily on large field-erected cooling tower applications, are available on Series 3000 Cooling Towers, for incremental thermal performance increases. This accessory can be used to gain extra capacity in tight layoyts,while maintaining the same footprint and unit horsepower. The velocity recovery stack height is f ive feet and can be constructed of either hot-dip galvanized steel, the Corrosion Protection System, or Type 304 stainless steel. Field assembly is required. Your local OMRAN Representative can provide additional application assistance. Optional EASY CONNECT Piping Arrangement with BALANCE CLEAN Chamber 10
Optional Accessories Vibration Cutout Switch A factory-mounted vibration cutout switch is available to effectively protect against equipment failure due to excessive vibration of the mechanical equipment system. OMRAN can provide either a mechanical or solid-state electronic vibration cut-out switch to ensure reliable protection and troublefree operation in the moist cooling tower environment. Additional contacts can be provided to either switch to activate an alarm or initiate equipment shutdown. Ladder, Safety Cage, Gate and Handrails If the installation owner desires access to the cooling tower fan deck using ladders, OMRAN equipment can be provided with ladders extending from the top of the unit to the base, as well as safety cages, safety gates and handrail packages to meet requirements. All access to the top of the equipment must be made in accordance with applicable gove rnmental occupational safety standards. Internal Walkway and Service Platforms, and External Service Platforms A galvanized steel internal walkway located between the two access doors of the cooling tower provides a permanent working surface for easy access to the strainer, outlet, and make-up water assembly. For access options to the motor and drive assemblies on two-piece units, an internal ladder and upper service platform with handrail is available. For external service, louver face platforms, access door platforms and fan deck extensions are other options that can be added to the cooling tower either when the unit is purchased or as an aftermarket item. Safety gates are available for all handrail openings supplied by OMRAN. Internal walkway External platform at louver face Internal ladder and service platform 11
Basin Heaters Cooling towers exposed to below freezing ambient temperatures require protection to prevent freezing of the water in the cold water basin when the unit is idle. Factory-installed heaters, which maintain +40 F water temperature at 0 F, are a simple and inexpensive way of providing such protection. Heater Sizing Data Model Numbers 1 Standard heaters sized for 0º F ambient. 2 HARD heaters sized for -20 ºF ambient. Standard Heaters 1 HARD Heaters 2 No. of Heaters kw per Heater No. of Heaters kw per Heater 3240A thru 3379A 2 6 2 9 3412A thru 3527A 2 8 2 12 3473A thru 3672A 2 10 2 14 3728A thru 31056A 2 12 2 15 3583A thru 3725A 2 14 2 18 31132A thru 31301A 2 14 2 20 Electric Water Level Control Package The electric water level control replaces the standard mechanical makeup valve when a more accurate water level control is required. This package consists of a conductance-actuated level control mounted in the basin and a slow-closing solenoid in the make-up water line. For water supply pressure greater than 40 psig, a surge suppressor may be required (by others). Air Inlet and Basin Debris Screens Hot-dip galvanized wire mesh screens can be factory-installed over the inlet louvers to prevent debris from entering the tower. As an alternative to air inlet screens, HDG wire mesh screens are factory-installed over exposed portions of cold water basin to keep out airborne debris. Basin Sweeper Piping Basin sweeper piping provides an effective method of eliminating debris which may collect in the cold water basin of the tower. A complete piping system including nozzles is provided in the tower basin for connection to side stream filtration equipment (by others). Side Outlet Depressed Sump Available for field installation below the base of tower to facilitate job site piping. The outlet connection is designed to mate with ASME Class 150 flat face flanges. High Temperature Wet Deck Optional high temperature wet deck material is available for entering water temperatures up to 135 F. Extended Lubrication Lines Extended lubrication lines with standard grease fittings are available for lubrication of the fan shaft bearings. Fittings are located inside the plenum area next to the access door. 12
Engineering Data Do not use for construction. Refer to factory certified dimensions. This brochure includes data current at time of publication which should be reconf irmed at the time of purchase. Single Cell Unit NOMINAL MOTOR FAN WEIGHTS (lbs) DIMENSIONS MODEL TONS HP CFM OPER. SHIPPING HEAVIEST NUMBER (1) (2) SECTION L W H A 3240A 240 10 62790 14770 6790 6790 3272A 272 15 71340 14900 6920 6920 8'-5 3/4" 18'-0 1/2" 9'-3 5/8" 8'-7 3/4" 3299A 299 20 78110 14960 6980 6980 3333A 333 20 85720 15750 7260 7260 3358A 358 25 91960 15780 7290 7290 8'-5 3/4" 18'-0 1/2" 10'-7 5/8" 9'-11 3/4" 3379A 379 30 97400 15830 7340 7340 3412A 412 25 103700 18580 8420 8420 9'-9 1/4" 20'-0 1/2" 10'-9 1/8" 9'-11 3/4" 3436A 436 30 109830 18630 8470 8470 3455A 455 25 112250 19480 8740 8740 3482A 482 30 118880 19530 8790 8790 9'-9 1/4" 20'-0 1/2" 12'-1 1/8" 11'-3 3/4" 3527A 527 40 130160 19690 8950 8950 3473A 473 25 118870 23090 10190 10190 11'-9 3/4" 21'-6 1/2" 10'-10 1/8" 9'-11 3/4" 3501A 501 30 125900 23140 10240 10240 3552A 552 30 136170 25690 10800 10800 3604A 604 40 149090 25850 10960 10960 11'-9 3/4" 21'-6 1/2" 12'-2 1/8" 11'-3 3/4" 3648A 648 50 159950 25860 10970 10970 3672A 672 60 166020 27060 12180 12180 3728A 728 40 178860 32060 13770 8720 3781A 781 50 191890 32070 13780 8730 11'-9 3/4" 21'-6 1/2" 16'-4 7/8" 15'-5 1/2" 3828A 828 60 203230 32290 13990 8940 3872A 872 50 206630 35030 14500 8800 3923A 923 60 218840 35250 14710 9010 11'-9 3/4" 21'-6 1/2" 19'-0 7/8" 18'-1 1/2" 3970A 970 75 230080 36530 16000 10300 3985A 985 60 229950 40240 15560 9460 11'-9 3/4" 21'-6 1/2" 21'-8 7/8" 20'-9 1/2" 31056A 1056 75 246700 40330 15650 9550 3583A 583 25 143950 30300 12070 12070 3618A 618 30 152460 30350 12120 12120 13'-11 1/8" 24'-0 1/2' 12'-3 1/8" 11'-3 3/4" 3676A 676 40 166920 30510 12280 12280 3725A 725 50 179080 30520 12290 12290 31132A 1132 75 267880 41290 16610 10230 13'-11 1/8" 24'-0 1/2" 19'-2 7/8" 18'-1 1/2" 31213A 1213 75 282010 44300 17550 10720 13'-11 1/8" 24'-0 1/2" 21'-10 7/8" 20'-9 1/2" 31301A 1301 100 302580 46590 1 9840 13010 Notes: 1. A nominal ton is defined as 3 GPM of water cooled from 95 F to 85 F with a 78 F entering wet bulb. 2. Operating weight is for tower with the water level in the cold water basin at overflow. If a lower operating weight is needed to meet design requirements, your local OMRAN sales representative can provide additional assistance. 3. 31301A is supplied with gear drive as standard. 4. Models 3240A 3672A and 3583A 3725A, when shipped with a gear drive, will have increased unit height by 10 1/2". 5. Refer to page 15 for dimensional reference drawings. 13
Double Cell Unit NOMINAL MOTOR FAN WEIGHTS (lbs) DIMENSIONS MODEL TONS HP CFM OPER. SHIPPING HEAVIEST NUMBER (1) (2) SECTION L W H A 3240A-2 480 (2) 10 125580 29540 13580 6790 3272A-2 544 (2) 15 142680 29800 13840 6920 17'-2" 18'-0 1/2" 9'-3 5/8" 8'-7 3/4" 3299A-2 598 (2) 20 156220 29920 13960 6980 3333A-2 666 (2) 20 171440 31500 14520 7260 3358A-2 716 (2) 25 183920 31560 14580 7290 17'-2" 18'-0 1/2" 10'-7 5/8" 9'-11 3/4" 3379A-2 758 (2) 30 194800 31660 14680 7340 3412A-2 824 (2) 25 207400 37160 16840 8420 19'-9" 20'-0 1/2" 10'-9 1/8" 9'-11 3/4" 3436A-2 872 (2) 30 219660 37260 16940 8470 3455A-2 910 (2) 25 224500 38960 17480 8740 3482A-2 964 (2) 30 237760 39060 17580 8790 19'-9" 20'-0 1/2" 12'-1 1/8" 11'-3 3/4" 3527A-2 1054 (2) 40 260320 39380 17900 8950 3473A-2 946 (2) 25 237740 46180 20380 10190 23'-10" 21'-6 1/2" 10'-10 1/8" 9'-11 3/4" 3501A-2 1002 (2) 30 251800 46280 20480 10240 3552A-2 1104 (2) 30 272340 51380 21600 10800 3604A-2 1208 (2) 40 298180 51700 21920 10960 23'-10" 21'-6 1/2" 12'-2 1/8" 11'-3 3/4" 3648A-2 1296 (2) 50 319900 51720 21940 10970 3672A-2 1344 (2) 60 332040 54120 24360 12180 3728A-2 1456 (2) 40 357720 64120 27540 8720 3781A-2 1562 (2) 50 383780 64140 27560 8730 23'-10" 21'-6 1/2" 16'-4 7/8" 15'-5 1/2" 3828A-2 1656 (2) 60 406460 64580 27980 8940 3872A-2 1744 (2) 50 413260 70060 29000 8800 3923A-2 1846 (2) 60 437680 70500 29420 9010 23'-10" 21'-6 1/2" 19'-0 7/8" 18'-1 1/2" 3970A-2 1940 (2) 75 460160 73060 32000 10300 3985A-2 1970 (2) 60 459900 80480 31120 9460 23'-10" 21'-6 1/2" 21'-8 7/8" 20'-9 1/2" 31056A-2 2112 (2) 75 493400 80660 31300 9550 3583A-2 1166 (2) 25 287900 60600 24140 12070 3618A-2 1236 (2) 30 304920 60700 24240 12120 28'-0 3/4" 24'-0 1/2' 12'-3 1/8" 11'-3 3/4" 3676A-2 1352 (2) 40 333840 61020 24560 12280 3725A-2 1450 (2) 50 358160 61040 24580 12290 31132A-2 2264 (2) 75 535760 82580 33220 10230 28'-0 3/4" 24'-0 1/2" 19'-2 7/8" 18'-1 1/2" 31213A-2 2426 (2) 75 564020 88600 35100 10720 28'-0 3/4" 24'-0 1/2" 21'-10 7/8" 20'-9 1/2" 31301A-2 2602 (2) 100 605160 93180 39680 13010 14
Single Cell Unit Double Cell Unit *** 3728A THRU 31056A AND 31132A THRU 31301A SHIP IN TWO SECTIONS PER CELL. THE TOP SECTION IS THE HEAVIEST AND TALLEST. TOP SECTION HEIGHTS ARE: 3728A THRU 3970A: 10-3 1/8 31132A: 10-5 1/8 3985A THRU 31056A: 11 «- 7 1/8 31213A THRU 31301A: 11 «- 9 1/8 15
Support Details The recommended support arrangement for the Series 3000 Cooling Tower consists of parallel I-beams positioned as shown in the drawings. Besides providing adequate support, the steel also serves to raise the unit above any solid foundation to assure access to the bottom of the tower. Series 3000 Cooling Towers may also be supported on columns at the anchor bolt locations shown in Plan A or Plan C. To support a Series 3000 Cooling Tower on columns, or in an alternate steel support arangement, consult your OMRAN Representative. A minimum bearing surface of twelve inches square must be provided under each of the concentrated load points (See Note 7). WEIGHTS (LBS.) DIMENSIONS MODEL SHIPPING OPER. WT.AT NUMBER (1) (1&2) L1 L2 W A B C D E 3240A 6790 14770 3693 3272A 6920 14900 3725 8'-5 3/4" 17'-2" 18'-0 1/2" 9'-4" 16'-4 1/2" 1 1/8" 8'-3 1/2" 4 3/4" 3299A 6980 14960 3740 3333A 7260 15750 3938 3358A 7290 15780 3945 8'-5 3/4" 17'-2" 18'-0 1/2" 9'-4" 16'-4 1/2" 1 1/8" 8'-3 1/2" 4 3/4" 3379A 7340 15830 3958 3412A 8420 18580 4645 9'-9 1/4" 19'-9" 20'-0 1/2" 11'-4" 18'-4 1/2" 1 1/8" 9'-7" 43/4" 3436A 8470 18630 4658 3455A 8740 19480 4870 3482A 8790 19530 4883 9'-9 1/4" 19'-9" 20'-0 1/2" 11'-4" 18'-4 1/2" 1 1/8" 9'-7" 4 3/4" 3527A 8950 19690 4923 3473A 10190 23090 5773 11'-9 3/4" 23'-10" 21'-6 1/2" 12'-10" 19'-10 1/2" 1 1/8" 11'-7 1/2" 4 3/4" 3501A 10240 23140 5785 3552A 10800 25690 6423 3604A 10960 25850 6463 11'-9 3/4" 23'-10" 21'-6 1/2" 12'-10" 19'-10 1/2" 1 1/8" 11'-7 1/2" 4 3/4" 3648A 10970 25860 6465 3672A 12180 27060 6765 3728A 13770 32060 8015 3781A 13780 32070 8018 11'-9 3/4" 23'-10" 21'-6 1/2" 12'-10" 19'-10 1/2" 1 1/8" 11'-7 1/2" 4 3/4" 3828A 13990 32290 8073 3872A 14500 35030 8758 3923A 14710 35250 8813 11'-9 3/4" 23'-10" 21'-6 1/2" 12'-10" 19'-10 1/2" 1 1/8" 11'-7 1/2" 4 3/4" 3970A 16000 36530 9133 3985A 15560 40240 9258 11'-9 3/4" 23'-10" 21'-6 1/2" 12'-10" 19'-10 1/2" 1 1/8" 11'-7 1/2" 4 3/4" 31056A 15650 40330 9298 3583A 12070 30300 7575 3618A 12120 30350 7588 3676A 12280 30510 7628 13'-11 1/8" 28'-0 3/4" 24'-0 1/2" 15'-4" 22'-4 1/2" 1 7/16" 13'-8 1/4" 5 3/8" 3725A 12290 30520 7630 31132A 16610 41290 10323 13'-11 1/8" 28'-0 3/4" 24'-0 1/2" 15'-4" 22'-4 1/2" 1 7/16" 13'-8 1/4" 5 3/8" 31213A 17550 44300 11075 13'-11 1/8" 28'-0 3/4" 24'-0 1/2" 15'-4" 22'-4 1/2" 1 7/16" 13'-8 1/4" 5 3/8" 31301A 19840 46590 11648 16 See notes on page 17.
Single Cell Units Plan B Plan A Double Cell Units Note: 1. Shipping and operating weight are for a single cell. To obtain weights for multi-cell units, multiply by number of cells. 2. Operating weight and weight loading are for a single cell tower with water at overflow level in the cold water basin. 3. Support beams and anchor bolts to be selected and installed by others. 4. All support steel must be level at the top. 5. Beams must be selected in accordance with accepted structural practice. Maximum deflection of beam under unit to be 1/360 of span, not to exceed 1/2 inch. 6. All single and double cell units can be furnished with optional vibration isolation rail packages, when required, to be used between the tower and supporting steel. The OMRAN standard vibration isolation rail package is designed for support Plan A for single cell units and support Plan C for double cell units. Plan B rails are available upon request. When determining the length of the supporting steel, allow for the length of the vibration rails as they are sometimes longer than the cooling tower dimensions shown. 7. If point vibration isolation is used with multi-cell towers, the isolators must be located under the support steel, not between the support steel and the cooling towers. Plan C 17
Series 3000 Rigging and Assembly Instructions Introduction Series 3000 Cooling Towers should be rigged and assembled as outlined in this bulletin. These procedures should be thoroughly reviewed prior to the actual rigging and assembly of the equipment to acquaint all personnel with procedures to be followed and to assure that all necessary equipment will be available. Be sure to have a copy of the certified drawing available for reference. If you do not have a copy of this drawing, or if you need additional information about this unit, contact the local OMRAN Representative whose name and telephone number are on a label adjacent to the access door. The model number and serial number of the unit are also located in this area. SHIPPING Series 3000 units are factory assembled to assure uniform quality and minimum field assembly. Models 3240A through 3672A, and 3583A through 3725A ship in one section per cell. All other Series 3000 models ship in two sections per cell (upper and lower) due to shipping height restrictions. CHECK UNIT BEFORE RIGGING When the unit is delivered to the jobsite, it should be checked thoroughly to ensure all required items have been received and are free of any shipping damage prior to signing the bill of lading. The following parts should be inspected: Sheaves and Belts Bearings Bearing Supports Fan Motor(s) Fan(s) and Fan Shaft(s) Float Valve Assembly(s) Water Distribution System Wet Deck Surface Cold Water Basin Strainer(s) Interior Surfaces Exterior Surfaces Optional EASY CONNECT Piping Arrangement and BALANCE CLEAN Chamber Miscellaneous Items: All bolts, nuts, washers, and sealer tape required to assemble sections or component parts are furnished by OMRAN. and shipped with the unit. A checklist inside the envelope attached to the side of the unit marked For Rigger indicates what miscellaneous parts are included with the shipment and where they are packed. UNIT WEIGHTS Before rigging any unit, the weight of each section should be verified from the unit certified drawing. Some accessories add additional weight as shown on the respective accessory drawings. WARNING: Before an actual lift is undertaken, ensure that no water, snow, ice, or debris has collected in the basin or elsewhere in the unit. Such accumulations will add substantially to the equipment s lifting weight. WARNING: For safety, in the event of extended lifts or where hazards exist, the lifting devices should be used in conjunction with safety slings placed under the unit. ANCHORING Three-quarter inch (3/4") diameter holes are provided in the bottom flange of the cold water basin section for bolting the unit to the support beams. Refer to the suggested support location drawing included in the submittal for the location of the mounting holes. The unit must be level for proper operation. Anchorage bolts must be provided by others. Additional anchorage plates are supplied to meet Seismic Zone 4 and/or additional wind loading requirements. PIPING Refer to the recommended piping drawing included in the submittal package for details on inlet piping arrangement and support. Safety Adequate precautions appropriate for the installation and location of these products should be taken to safeguard the public from possible injury and the equipment and premises from damage. WARNING When the fan speed of any unit is to be changed from the factory set speed, including the use of a variable speed device, steps must be taken to avoid operating at or near the fan s critical speed which could result in fan failure and possible injury or damage. Consult with your local OMRAN. Representative on any such applications. WARNING Operation, maintenance and repair of this equipment should be undertaken only by personnel qualified to do so. Proper care, procedures and tools must be used in handling, lifting, installing, operating, maintaining and repairing this equipment to prevent personal injury and/or property damage. Warranties Please refer to the Limitation of Warranties applicable to and in effect at the time of the sale/purchase of these products. Freeze Protection These products must be protected by mechanical and operational methods against damage and/or reduced effectiveness due to possible freeze-up. Please refer to the Series 3000 catalog, Operation and Maintenance Manual or contact the local OMRAN. Representative for recommended protection alternatives. Location All evaporative cooling equipment must be located to ensure an adequate supply of fresh air to the fans. When units are located adjacent to walls or in enclosures, care must be taken to ensure that the warm, saturated, discharge air is not deflected and short-circuited back to the air intakes. Also, each unit should be located and positioned to prevent the introduction of discharge air into the ventilation systems of the building on which the unit is located and of adjacent buildings. For detailed recommendations on Series 3000 Cooling Tower layout, please consult your local OMRAN Representative. 18
Refer to Table 1and Figures 1 & 2for the recommended size of the spreader bar (dimension W ) and the recommended minimum vertical dimension H from the lifting device at the base of each unit or section to the spreader bar. The lifting device can be moved to the alternative lifting device location shown infigure 2 for final positioning of multi-cell units. Bolt holes have been provided to accommodate the lifting devices at this alternative location. For units shipped in two sections and all multi-cells, refer to the appropriate section of this bulletin for further details. Note: Models 3728A through 31056A, and 31132A through 31301A must be rigged one section at a time. Table 1 - Rigging Dimensions Figure 1 Figure 2 Model Number 3240A to 3379A 3412A to 3527A 3473A to 3501A 3552A 3604A 3648A 3672A 3583A 3618A 3676A 3725A 3728A to 3828A 3872A to 3970A 3985A to 31056A 31132A 31213A to 31301A Dimensions (for each cell) Section H Min. W 1 piece 1 piece 1 piece 1 piece upper lower upper lower upper lower upper lower upper lower 15' 17' 18' 18' 18' 18' 18' 18' 18' 20' 20' 20' 20' Note: H dimension represents distance from the lifting device at the base of the tower section to spreader bar attach points. W1 dimension represents minimum distance between spreader bar attach points. 20' 8'6" min. 10' 12' 14' 12' 12' 12' 12' 12' 12' 14' 14' 14' 14' FIGURE 1 Series 3000 Models 3240A through 3672A or 3680A and 3583A through 3725A FIGURE 2 Series 3000 Two-Section Units Section Assembly Position the bottom section on the unit support and bolt in place. Factory installed sealer tape is furnished on the mating flange of the bottom section to ensure a watertight seal between the top and bottom section. Remove the protective paper strip from the sealer tape. Using drift pins in the bolt holes provided, guide the top section onto the bottom section. Match marks must line up as shown in Figure 3. Bolt in place as illustrated in Figure 3 (Detail A) using a sealing washer under each nut to prevent water leakage. Note: On multi-cell installations, it is suggested that for cells subsequent to the first, have the top and bottom sections assembled on the support foundation adjacent to the final mounting locations. This will allow space for securing the top and bottom sections of each cell. Move the subsequent cell(s) to their final position using the lifting devices at the base of the cell(s). Refer to the section Assembly of Multiple-Cell Units for details. All multi-cell units have the cell number and face identified on each section as well as match marks to show how the cells should be mated. FIGURE 3 Upper and Lower Assembly 19
Assembly of Multi-Cell Towers Refer to the unit certified print for the proper orientation of each cell.the cell number and face are stenciled on the outer basin wall. Multiple cell cooling tower installations may employ cold water basin connectors to equalize the water level in the basin of each cell. Figure 4details the connector for Series 3000 Cooling Towers. When used, basin connectors must be assembled as the cells are being positioned on the tower supports. Follow directions below for details on their installation. For two-section cells, first attach the unit bottom section of the first cell to the foundation. Then fasten the unit s top section to the secured bottom section. Each subsequent cell should be assembled just adjacent to its final location, and then positioned next to the previous cell. Relocate the lifting devices at the base of each subsequent cell to slide the cells together. This can be seen in Figure 2. Use the basin connector assembly procedure outlined below to join the basin connection for multi-cell units. 1. Position Cell #1 on the unit support and bolt into place. 2. Wipe down the surface adjacent to the opening of Cell #1 to remove any dirt or moisture that may have accumulated during shipment. 3. Wipe down the flanges on both ends of the basin connector. On one end apply a layer of 1/8" x 1" butyl tape around the face of the flange over the centerline of the holes. Do not overlap or stretch too thinly at the corners. When it is necessary to splice the sealer, be sure to press the two ends together so as to form a smooth continuous strip. Apply a second layer of sealer tape over the first layer following the same procedure. Refer to Figure 4 Detail A. 4. Using drift pins to align the bolt holes, place the basin connector over the opening in the tower basin of Cell #1 and fasten in place. Insert the 3/8" self-tapping screws or bolts from the basin connector into the basin wall as illustrated in Figure 5. Note: Basin connectors furnished with units constructed with stainless steel basins are assembled with stainless steel bolts, washers and nuts in lieu of self tapping screws. 5. Apply sealer to the other end of the basin connector as described in Step 3. 6. Position Cell #2 on the tower supports. Wipe down the surface adjacent to the opening to remove any dirt or moisture. 7. Using drift pins to assure alignment, draw Cell #2 tight against the basin connector. The Series 3000 Unit lifting devices must be moved to the alternative lifting device location as referred to in the Rigging section of this bulletin to assist in this step. (Figure2) 8. As illustrated in Figure 5, insert 3/8" self-tapping screws in each hole from the basin connector into the basin wall and tighten. FIGURE 5 FIGURE 4 Positive Closure Plate Option The optional Positive Closure Plate and gasket can be furnished on multiple cell units to allow individual cells to be isolated for cleaning and routine maintenance. This plate ships loose inside the unit cold water basin. To install the Positive Closure Plate and gasket, follow steps 1 through 7 from the instructions above. Complete the installation of your specific type of tower using the instructions listed below. Thread 3/8" self-cutting bolts from the basin connector into the cell with the Positive Closure Plate, as shown in Figure 6. Position the neoprene gasket and Positive Closure Plate over the bolts and fasten in place with the 3/8" flat washers and wing nuts provided. FIGURE 6 20
Installation Of Fan Guar d Due to height limitations on truck shipments, the fan guard may ship unmounted. Models 3240A through 3379A have a one-piece fan guard. The fan guards on Models 3583A, 3618A, 3676A, 3725A and models 31132A through 31301A have a four-piece fan guard. The fan guard supports should be joined as illustrated in Figure 7, Detail A before securing to the fan cylinder as illustrated in Figure 7, Detail B. The fan guards should be joined together and to the fan guard support as illustrated in Figure 7, Detail C before securing to the fan cylinder as illustrated in Figure 7, Detail D. All other models are shipped in two halves. These halves should be bolted together using fan guard clamps, 3/8" bolts and lock nuts supplied with unit. Then attach the guard to the fan cylinder as illustrated in Figure 7, Detail D. Fan guards must be securely in place before the Series 3000 Cooling Tower is placed in operation. DETAIL D: ATTACH FAN GUARDS TO FAN CYLINDER USING 3/8" FLAT- WASHERS AND LOCKNUTS SUPPLIED FIGURE 7 DETAIL B: BOLT FAN GUARD SUPPORTS TO FAN CYLINDER USING 3/8" FLATWASHERS AND LOCKNUTS SUPPLIES DETAIL A: BOLT FAN GUARD SUPPORTS TOGETHER USING 3/8" BOLTS, FLAT- WASHERS, AND LOCKNUTS SUPPLIED DETAIL C: BOLT FAN GUARDS TOGETHER AND TO FAN GUARD SUPPORTS USING FAN GUARD CLAMPS, 3/8" BOLTS, AND LOCKNUTS SUPPLIED Installation of the Optional Side Outlet Depressed Sump Box The optional side outlet depressed sump box option allows a Series 3000 Cooling Tower water outlet connection to be piped from underneath the unit in four possible directions, 90 apart. The connection is a bolt circle to fit a 150-pound ASA flat flange with a full-face gasket. To install the side outlet depressed sump box, follow steps below. 1. Wipe the edges around the opening in the cold water basin to remove any dirt or moisture that may have accumulated during shipment. Apply a layer of 1/8" x 1" butyl sealer tape around the opening in the basin over the centerline of the holes. Do not stretch the sealer too thinly or overlap at the corners. When it is necessary to splice the sealer, be sure to press the two ends together to form a continuous strip. Apply a second layer of sealer tape over the first layer following the same procedure. Refer to Figure 8. 2. Insert the basin box assembly into the opening in the cold water basin and attach it to the basin with 3/8" x 1" bolt and nuts, flat washers, and lock washers as shown in Figure 8, Detail A. 3. Place the suction strainer over the opening. Optional Accessories and Equipment All optional accessories such as ladders, safety cages, platforms, and deck grating between cells should be installed as shown on the appropriate reference drawing in the submittal package from Baltimore Aircoil Company. The handrail package reference drawing is included with the unit in the envelope attached to the side of the unit marked For Rigger. FIGURE 8 Detail A 21
Series 3000 Crossflow Cooling Tower Operating and Maintenance Instructions OMRAN TAHVIEH Company Crossflow Cooling Towers have been designed to give long, troublefree service when properly installed, operated, and maintained. To obtain optimum performance and maximum service life, it is important that a program of regular inspection and maintenance be developed and carried out. This bulletin is published as a guide to establishing such a program. Included in this bulletin are the recommended maintenance services for start-up, operation, and shutdown and the approximate frequency for each. Note that the recommendations on frequency of service are minimums and where operating conditions are severe, the services should be performed more often. For each required service, follow the procedures outlined under the ÒMaintenance ProceduresÓsection of this bulletin. The Series 3000 Cooling Tower is illustrated on page 23 with the major points of inspection and service identified. A copy of the unit certified drawing should also be available for reference. If you need additional information about the operation or maintenance of this equipment that is not covered in this bulletin, contact the local OMRAN. Representative. Their name and telephone number are on a label adjacent to the access door. The model and serial number of the unit are also located in this area. Table of Contents Page General Maintenance Information.... 23 Operation and Maintenance................. 24 Initial and Seasonal Start-Up............... 25 Operation............................. 25 Seasonal Shutdown...................... 25 Maintenance Procedures................... 26 Hot Water Basins... 26 ColdWaterBasin... 26 BALANCECLEANChamber... 26 Make-UpValve... 27 Fan Motor............................. 27 Fan Shaft Bearings...................... 28 Adjustable Motor Base................... 28 BALTIDRIVE Power Train Drive System..... 28 Corrosion Protection...................... 29 Winter Operation......................... 30 WaterTreatment... 31 Biological Control........................ 32 22
General Maintenance Information The services required to maintain a cooling tower are primarily a function of the quality of the air and water in the locality of the installation: AIR: The most harmful atmospheric conditions are those with unusual quantities of industrial smoke, chemical fumes, salt or heavy dust. Such airborne impurities are carried into the cooling tower and absorbed by the recirculating water to form a corrosive solution. WATER: The most harmful conditions develop as water evaporates from the cooling tower, leaving behind the dissolved solids originally contained in the make-up water. These dissolved solids may be either alkaline or acidic and, as they are concentrated in the circulating water, can produce scaling or accelerated corrosion. The extent of impurities in the air and water determines the frequency of most maintenance services and also governs the extent of water treatment which can vary from a simple continuous bleed and biological control to a sophisticated treatment system. (See Water Treatment and Biological Control. ) Top Water Inlet Fan Corrosion Resistant Fan Sheave Fan Motor Casing Fan Deck Air Inlet Louvers Wet Deck Surface with Integral Drift Eliminators Make-up Valve Adjustable Float Cold Water Basin Water Outlet Suction Strainer Figure 1 Cutaway view of Series 3000 Cooling Tower Optional EASY CONNECT Piping Arrangement with BALANCE CLEAN Chamber 2 Figure 2 Series 3000 BALANCE CLEAN Chamber 23
Operation and Maintenance Described below are the recommended services for start-up, operation, and shutdown and the approximate frequency for each. TABLE 1: Recommended Maintenance Services for Series 3000 Cooling Tower Type of Service Monthly Quarterly Start-Up Shutdown Annually Ref. Page Inspect General Condition of Tower X X 4 Inspect and Clean as Necessary: A) Cold Water and Hot Water Basins X X X 5 Flush Cold Water Basin to Remove Silt X 6 B) Optional BALANCE CLEAN Chamber Inlet Strainer X X X 5 C) Air Inlet Louvers X X X 4 Check and Adjust Water Level in: Cold Water Basin/ Hot Water Basin X X 5 Check Operation of Make-Up Valve X X 6 Check Bleed Rate and Adjust X X 10 BELTIDRIVE Power Train: A) Check Condition of Belt X X 78 & B) Readjust Tension on Belt X 8 C) Drive Alignment 8 X & 7 Lubricate Fan Shaft Bearings X X X 7 Lubricate Motor Base Adjusting Screw X X X 7 Clean Outside of Fan Motor X X X 6 Inspect Protective Finish X 8 NOTES: 1. Recommended service intervals are for typical installations. Severe environment conditions may dictate more frequent servicing. 2. When operating in ambient temperatures below freezing, the cooling tower should be inspected more frequently (see Winter Operation, page 30). 3. Tension on new belts must be readjusted after first 24 hours of operation and quarterly thereafter. WARNING: Before performing any maintenance or inspection, make certain that all electrical power has been disconnected and locked in the off position SAFETY PRECAUTIONS: The operation, maintenance, repair of this equipment should be under taken only by qualified personnel. All qualified personnel should be thoroughly familiar with the equipment, the associated system and controls, and the procedures set forth in this manual. Proper care, procedures, and tools must be used in handling, lifting, installing, operating, maintaining and repairing this equipment to prevent personal injury and/or property damage. All electrical, mechanical, and rotating machinery constitute a potential hazard, par ticularly for those not familiar with the design, construction, and operation. Accordingly, adequate safeguards (including the use of protective enclosures where necessary) should be taken with this equipment both to safeguard the public (including minors) from injury and to prevent damage to the equipment, its associated system, and the premises. The cooling towers are designed so that access to the top of the cooling tower is not required to perform routine maintenance. The top horizontal surface of the tower is not intended for use as a walking surface or working platform. If access to the top of the unit is desired, the purchaser/end-user is cautioned to use appropriate means, complying with applicable safety standards of governmental authorities. At no time should this equipment be operated without all fan screens, access panels, and access doors in place. WARNING: When the fan speed of the cooling tower is changed from the factory set speed, including changes achieved by the use of a variable fan speed control device, steps must be taken to avoid operating at or near the fan s critical speed which could result in fan failure and possible injury or damage. Consult with your local OMRAN Representative on any such applications. WARNING: For the protection of authorized service and maintenance personnel, each fan and pump motor associated with this equipment should be installed with a lockable disconnect switch located within sight of the cooling tower. No service work should be performed on or near the fans, motors, and drives or inside the unit without first ensuring the fan and pump motors have been disconnected and locked out. WARNING: The recirculating water system may contain chemicals or biological contaminants, including Legionella, which could be harmful if inhaled or ingested. Accordingly, personnel who may be exposed directly to the discharge airstream and the associated drift, mists generated during operation of the water distribution system and/or fans, or mists produced by high pressure water jets or compressed air (should these be used to clean portions or components of the recirculating water system), should wear respiratory protection equipment approved for such use by local occupational safety and health authorities. WARRANTIES: Please refer to the Limitation of Warranties applicable to and in effect at the time of sale/purchase of these products. Freeze Protection: These products must be protected by mechanical and operational methods against damage and/or reduced effectiveness due to possible freeze-up. Please refer to the product catalog or contact the local OMRAN Representative for recommended protection alternatives. 24
Operation and Maintenance (continued) INITIAL AND SEASONAL START-UP: Prior to initial start-up or after a shut down period, the cooling tower must be thoroughly inspected and cleaned: 1. Clean all debris, such as leaves and dirt, from inside the tower, and the air inlet louvers. 2. Remove the inlet strainer, clean and install on all Series 3000 Cooling Towers provided with the optional BALANCE CLEAN Chamber. 3. Drain the cold water basin (with basin strainers in place) and flush to remove accumulated dirt. 4. Remove the suction strainer, clean and reinstall. 5. Turn the fan(s) by hand to insure rotation without obstruction. 6. Start the fan motor(s) and check for proper fan rotation. 7. At seasonal start-up, adjust the belt tension on the Beltdrive Power Train fan drive system. Note, during initial start-up, the belt tension may not require adjusting since the drive has been properly tensioned at the factory prior to shipment. 8. Check float operated make-up valve to be sure it is operating freely. 9. Lubricate the fan shaft bearings prior to seasonal start-up. Note, this is not required at initial start-up since the fan bearings have been lubricated at the factory prior to shipment. 10. At start-up, when the cold water basin is completely drained, fill the cold water basin with fresh water to the overflow level. For new installations, initiate the biocide water treatment program at this time (see Biological Control Section). At seasonal start-up, and following a shutdown period of more than 3 days, resume the biocide treatment program or administer a shock treatment of appropriate biocides prior to operating the cooling tower fans to eliminate accumulated biological contaminants (see Biological Control Section). 11. Set the float on the make-up valve to shut off the valve when the float is approximately 1/2" below the overflow level. 12. Balance flow to the Series 3000 Cooling Tower(s) by adjusting the flow balancing valves (by others or optionally supplied by OMRAN). Adjustment to the balancing valves is not required if the unit is equipped with the optional EASY CONNECT Piping Arrangement with the BALANCE CLEAN Chamber. Multi-cell arrangements will require flow balancing between cells to obtain even water distribution. 13. Open the valve in the tower bleed line (by others) and adjust bleed to the recommended rate. (See Water Treatment page 31.) 14. Check the voltage and current of all three legs of the fan motor. The current should not exceed the nameplate rating. Note: Current should be measured during warm ambient conditions and with a heat load on the tower. After prolonged shutdowns, the motor insulation should be checked with a megger insulation tester prior to restarting the motor. CAUTION: Rapid on-off cycling can cause the fan motor to overheat. It is recommended that the controls be set to allow a maximum of 6 on-off cycles per hour. When using a 2-speed motor, the starter should include a 15- second time delay when switching from high speed to low speed. AFTER 24 HOURS: After 24 hours of operating the Series 3000 Cooling Tower under thermal load, the following services should be performed: 1. Check the tower for any unusual noise or vibration. 2. Check the operating water level in the hot and cold water basins. Adjust balancing valves and make-up float valve if necessary. 3. Readjust the belt tension. OPERATION: During operation, the tower should be inspected, cleaned, and lubricated on a regular basis. The required services and recommended frequency for each are summarized in Table 1 on page 24 of this bulletin. SEASONAL SHUTDOWN: The following services should be performed whenever the cooling tower is to be shutdown for more than 3 days: 1. Drain the cold water basin and all piping that will be exposed to freezing temperatures. 2. Clean and flush the hot and cold water basin with the basin strainers in place. Leave the cold water basin drain open so rain and melting snow will drain from the tower (for Series 3000 Cooling Towers with the optional BALANCE CLEAN Chamber, clean and flush the inlet strainer). 3. Clean the basin strainers and reinstall. 4. Cover the fan discharge opening to keep out dirt and debris. 5. Lubricate the fan shaft bearings and motor base adjusting screw. 6. Close the shutoff valve in the make-up water line (by others) and drain all exposed make-up water piping. 7. Inspect the integrity of the corrosion protection system on the steel portion of the tower. (See Corrosion Protection, page 29 ). 25
HOT WATER BASINS: Maintenance Procedures The system water enters the cooling tower through two hot water basins. The hot water basins and orifices must be kept clean. At design flow, the operating level should not be less than two inches or greater than five inches deep. Monthly, remove any dirt or debris which may clog the orifices. Seasonally clean and flush the hot water basin with fresh water. COLD WATER BASIN AND SUCTION STRAINERS: As the water circulating though the tower is cooled, it collects in the cold water basin and passes through the strainers into the system. The operating water level is controlled by the make-up valve and should be maintained at the operating water level shown in Table 2. The operating water level in the cold water basin will vary with system thermal load (evaporation rate), the bleed rate employed and the make-up water supply pressure. Because the typical winter load is less than the summer load, the winter evaporation rate is frequently less than the summer evaporation rate. With this reduced evaporation rate in winter, the water level in the cold water basin will increase unless the float is re-adjusted. The operating water level should be checked monthly and the float re-adjusted as necessary to maintain the recommended operating level. The water level in the cold water basin of units designed for remote sump operation is a function of the circulating water flow rate, water outlet connection size, quantity and location, and outlet piping size and configuration. Units designed for remote sump applications are not supplied with a water make-up assembly and the sump operating level is not adjustable during operation. The cold water basin should be inspected regularly. Any trash or debris which may have accumulated in the basin or on the strainers should be removed and, if necessary, the float adjusted to maintain the design operating level. SERIES 3000 OPTIONAL BALANCE CLEAN CHAMBER: The water to be cooled enters the tower through a single connection and passes through the BALANCE CLEAN Chamber. The device is equipped with an internal strainer. Located at the bottom of the BALANCE CLEAN Chamber is a capped clean-out connection. This can be used to periodically purge the BALANCE CLEAN Chamber of dirt and debris collected by the strainer. The strainer should be cleaned periodically as detailed in the Recommended Maintenance Schedule. This is accomplished by un-bolting and temporarily removing the chamber bottom plate and inspecting the strainer for dirt and debris. Optional Balance Clean Chamber Figure 4 Cold Water Basin Inspection Figure 3 26
6 Maintenance Procedures (continued) Quarterly, or more often if necessary, the entire cold water basin should be drained, cleaned, and flushed with fresh water to remove the silt and sediment which normally collects in the basin. It is important to note that the same maintenance applies to stainless steel basins or basins protected by the Corrosion Protection System. If not removed periodically, this sediment can become corrosive and cause deterioration of the protective finish of metallic basins. When flushing the basin, the strainers should be left in place to prevent the sediment from re-entering the tower system. After the basin has been flushed, the strainers should be removed, cleaned, and replaced before refilling the basin with fresh water. WARNING: Openings and/or submerged obstructions may exist in the bottom of the cold water basin. Use caution when walking inside this equipment. MAKE-UP VALVE: A float operated mechanical water make-up assembly is furnished as standard equipment on the cooling tower (unless the unit has been ordered with the optional electric water level control package or for remote sump application). It is located within easy reach from the access door at the connection end of the unit on the Series 3000 Cooling Towers. The standard make-up assembly consists of a bronze make-up valve connected to a float arm assembly and actuated by a large diameter polystyrene filled plastic float. The float is mounted on an all-thread rod which is held in place by wing nuts. The operating water level in the cold water basin can be adjusted by repositioning the float and all-thread rod using the wing nuts provided. The make-up assembly should be inspected monthly and adjusted as necessary. The valve itself should be inspected annually for leakage and the valve seat replaced if necessary. The make-up water supply pressure should be maintained between 15 and 50 psig for proper operation of the valve. To set the initial basin water level, adjust the wing nuts so that the make-up valve is completely closed when the water level in the cold water basin is 1/2" below the overflow connection. Under design thermal load and with average city water pressure (15 to 50 psig) at the valve, this setting should produce the operating water levels stated in Table 2. Note that if the thermal load is less than the design load at the time of unit start-up, the procedure may produce operating levels greater than that shown. It may be necessary to re-adjust the float in order to attain the recommended operating level. The unit basin should be closely monitored and water level adjusted as necessary during the first 24 hours of operation. Model No. Height of Water in the Cold Water Basin (in.) Series 3000 Models 8 3/4" 3240A to 3501A Series 3000 Models 9 3/4" 3552A to 31301A TABLE 2. Cold Water Basin Operating Water Level As an option, an electric water level control package is available in lieu of the above described mechanical make-up assembly. The package consists of a probe-type liquid level control assembly and a slow-closing solenoid valve. Stainless steel electrodes, factory-set at predetermined lengths, extend from an electrode holder into the cold water basin. These electrodes should be periodically cleaned to prevent accumulations of scale, corrosion, sludge or biological growth from interfering with the electrical circuit.with the electric water level control package, the water level is maintained at the recommended operating level regardless of the system thermal load. Therefore, it is not necessary, nor is it recommended that the operating level be adjusted. During the start-up of units equipped with the electric water level control package, the control unit should be bypassed in order to fill the unit 1/2" below the overflow connection. Operation at the recommended water level will ensure that the unit basin contains sufficient water volume to prevent air entrainment in the circulating pump during system start-up and to provide sufficient excess basin capacity to accept the total system pull-down volume. ( Pull-down volume is defined as that quantity of water suspended in the tower during operation plus that contained in the hot water basin, wet deck surface, external piping, and any heat exchangers which could drain to the tower cold water basin when the circulating pump is shut down.) FAN MOTOR: The standard fan motor used on Series 3000 Cooling Towers is a T.E.A.O. motor (Totally Enclosed, Air Over) with permanently lubricated ball bearings and special moisture protection on the bearings, shaft, and windings. The only servicing required during operation is to clean the outside surface of the motor at least quarterly to insure proper motor cooling. Additionally, after prolonged shutdowns, the motor insulation should be checked with a megger insulation tester prior to restarting the motor. 27
Maintenance Procedures (continued) FAN SHAFT BEARINGS: The fan shaft is supported by two pillow block ball bearings, each equipped with a lubrication fitting and a slinger/locking collar to keep out moisture. The bearings should be lubricated as follows: Initial Start-Up:Normally, no lubrication is required since the bearings have been lubricated at the factory prior to shipment. However, if the cooling tower has been stored at the job site for more than one year, bearings should be lubricated with new grease before initial operation. When lubricating, purge the old grease from the bearing by gradually adding grease until a bead of new grease appears at the seal on the underside of the bearing. ADJUSTABLE MOTOR BASE: The motor base adjusting screw should be coated twice a year using a good quality corrosion inhibiting grease. Adjusting Nut Lock Nut Adjustable Motor Base Series 3000 Figure 6 Adjusting Screw BELTIDRIVE POWER TRAIN: The BELTIDRIVE Power Train consists of a specially designed belt, with corrosion-resistant fan motor sheaves. The solid-backed, multi-groove, neoprene/polyester belt provides the premium quality necessary for cooling tower service. The corrosion-resistant sheaves extend the life of the belt by minimizing any possibility of rust or corrosion. These components provide a highly reliable system with low-maintenance requirements. The only service required on the BELTIDRIVE Power Train is to periodically check the condition of the belt and, when necessary, adjust the tension. The recommended service intervals are specified below: Upper and Lower Bearings Series 3000 Figure 5 Seasonal Start-Up:Purge both bearings with new grease prior to start-up. Operation: Lubricate bearings after every 2,000 hours of operation or once every three months, whichever occurs first. Seasonal Shutdown:Purge bearings with new grease prior to any prolonged storage or downtime. The fan shaft bearing should be lubricated only with a hand grease gun. Do not use high pressure grease guns since they may rupture the bearing seals. INITIAL START-UP: No servicing is required prior to initial tower start-up since the drive has been tensioned and aligned at the factory. SEASONAL START-UP: Readjust the tension on the belt. OPERATION: After the initial tower start-up or the installation of a new belt, the tension must be readjusted after the first 24 hours of operation. Thereafter, the condition of the belt should be checked quarterly and the tension adjusted as necessary, but at least once every three months. To check the belt tension, place a straight edge along the belt from sheave to sheave as shown in Figure 7a or use a tape measure as shown in Figure 7b to measure belt deflection. Apply a moderate force by hand (approximately 40 lbs) evenly across the width of the belt in the center of the span between the sheaves. If the belt deflects between 1/4" and 3/8" as shown in Figure 7a and 7b, the belt is adequately tensioned. 8 28